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Old 07-03-2013, 10:18 AM   #1
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Secondary Air Pump and Valve Replacement

The check engine light came on. My mechanic determined that my air valve was sticking, causing the pump to work harder, overheat and overcook the relay. The cost for repair is estimated at $1406, including a new pump ($600) relay and valve, and labor at $90/hr. Pelican lists the same pump from Bosch for $273. Has anyone here changed theirs? I keep my car (and my repair manuals) at my weekend place, so I can't get a handle on where the pump is and how complicated its replacement might be. I change my own brakes, oil, etc and do basic maintenance, but I wonder how many "wrenches" Wayne Dempsey would rate this project.
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Old 07-04-2013, 10:23 AM   #2
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SAI pump is located on the top of the engine on passenger side as shown below.

Removal is described in Figure 3 here: http://www.pelicanparts.com/techarticles/Boxster_Tech/15-ENGINE-Engine_Drop/15-ENGINE-Engine_Drop.htm

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Last edited by thstone; 07-04-2013 at 10:39 AM.
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Old 07-04-2013, 10:58 AM   #3
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the valve, however, is located on the engine under the passenger side intake plenum. at a minimum you'll have to remove the two crossover tubes to access it. worst case you have to pull the whole passenger side assembly off.
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Old 07-04-2013, 03:24 PM   #4
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Garage
What code caused the CEL? Could be as simple as a leaking hose or fitting.
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Old 07-06-2013, 03:22 AM   #5
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Thanks to All

Thanks to everyone who replied. In the long run, my mechanic - who I like and trust - permitted me to order the parts and will supply only the labor, freeing me up to play Uncle with the kids and not spend the holiday weekend in the garage. I assume that there will be lots more opportunities for me to "get to know" my car's innards. Happy 4th weekend.
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